Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
  • B44C5/00—Processes for producing special ornamental bodies
  • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
  • B44C5/0461—Ornamental plaques, e.g. decorative panels, decorative veneers used as wall coverings
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
  • B44C3/00—Processes, not specifically provided for elsewhere, for producing ornamental structures
  • B44C3/08—Stamping or bending
  • B44C3/085—Stamping or bending stamping
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
  • B44C5/00—Processes for producing special ornamental bodies
  • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
  • B44C5/0469—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
  • B44C5/0484—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper containing metallic elements
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44F—SPECIAL DESIGNS OR PICTURES
  • B44F9/00—Designs imitating natural patterns
  • B44F9/04—Designs imitating natural patterns of stone surfaces, e.g. marble
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H19/00—Coated paper; Coating material
  • D21H19/36—Coatings with pigments
  • D21H19/44—Coatings with pigments characterised by the other ingredients, e.g. the binder or dispersing agent
  • D21H19/46—Non-macromolecular organic compounds
  • D21H19/48—Diolefins, e.g. butadiene; Aromatic vinyl monomers, e.g. styrene; Polymerisable unsaturated acids or derivatives thereof, e.g. acrylic acid
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
  • D21H27/02—Patterned paper
  • D21H27/04—Patterned paper marbled
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
  • Y10T428/251—Mica

Definitions

• the invention relates to a process for the decorative coating of flat materials, in particular laminates or wood-based panels to achieve a marbled effect decor, by pressing a carrier web impregnated with curable aminoplast resin and coated with thermoplastic or thermosetting synthetic resin onto the substrate to be coated at melting or curing temperatures for the Resins and a carrier web containing synthetic resin for carrying out the method according to the invention.
• wood-based panels such as Chipboard, fiberboard, plywood, blockboard, cellulosic waste or laminates made from a plurality of layers of resin-containing core papers are coated with decoratively printed or dyed backing sheets, which are usually impregnated with aminoplast resins that can be hardened at elevated temperatures and coated with hardenable or thermoplastic condensation or polymerization resins.
• Products with particularly favorable usage properties are obtained if melamine-formaldehyde precondensates are used for the impregnation and curable polymerization resins, such as copolymers based on (meth) acrylic acid ester or unsaturated polyester resins, are used for the coating.
• This prior art is e.g. described in more detail in DE-C-2 734 669 and DE-C-3 403 691.
• Such carrier webs intended for surface treatment are generally produced in such a way that they are used as carrier webs used paper webs first impregnated with the aqueous solution of a curable aminoplast resin precondensate.
• the cellulose fibers of the carrier web are to be completely covered. This generally requires an amount of aminoplast resin (calculated as solid resin) of 50 to 100% of the paper weight.
• the webs obtained in this way are dried while avoiding complete curing of the aminoplast resin.
• the impregnated carrier webs can be coated in such a way that the coating resin is dissolved in a suitable solvent such as methylene chloride, methyl ethyl ketone, tetrahydrofuran or solvent mixtures and the solution obtained is poured onto the impregnated carrier web. The solvent is then evaporated off.
• the carrier web used for surface coating is printed or uni-colored to achieve a decorative surface with a decor that is tailored to the application.
• the transparent coating varnishes should let the decor or the uniform color shine through brilliantly and clearly.
• the remuneration of the flat beams, e.g. a particle board, with the carrier web comprising synthetic resin can be obtained by using a heating press at temperatures of about 130 to 180 ° C and a pressure of about 0.3 to 10 N / mm2 to apply the decorative, resin-coated carrier web to the carrier Press plate pressed.
• the resin cover layer assumes a degree of gloss corresponding to the surface of the press plate. It is also possible to harden the resin-coated carrier webs by themselves and then to glue them onto the carrier webs, if necessary using size presses.
• the formation of the laminate can be carried out simultaneously by pressing the core papers with hardening of the impregnating resins and the surface treatment in one operation.
• the remuneration of asbestos cement panels or plasterboard can be done. It is also possible to manufacture flat components, for example panels in honeycombs structure that may be covered with metal foil, such as aluminum foil.
• Such surface-coated flat materials combine good surface usage properties (abrasion resistance, scratch resistance, resistance to solvents) with a decorative, aesthetically pleasing effect.
• the tempered flat materials are therefore preferred for the production of objects with decorative surfaces, such as doors, furniture, table tops, facade elements, exhibition stands, or for the design of rooms such as foyers, waiting rooms, counter rooms, etc.
• the surfaces can also be structured.
• the structuring takes place during pressing by using a pressing tool with a relief-like surface, the structure of which is shown in negative form on the coating layer.
• special color effects can be achieved by pressing the colored first synthetic resin layer facing the pressing tool away from the raised areas of the pressing tool and draining off to the points of lower pressure.
• the color of the second resin layer and / or the color of the colored or printed carrier web can then be recognized in accordance with the raised locations of the profile of the pressing tool.
• Such a method is described in DE-A-2 650 560.
• the invention has for its object to temper sheet materials with synthetic resins to form a marbled effect decor.
• Marbled effect decor is an uneven distribution of the color-bound medium in the surface layer of the synthetic resin (s), which has a certain similarity to the color distribution in marble.
• the term flake-shaped pigment is understood to mean a flat pigment with a very small layer thickness.
• the particle size of the pigment is preferably 5 to 100 microns. This is to be understood as the areal expansion of the pigment.
• the layer thickness of the pigment is considerably smaller and is usually less than 1 ⁇ m.
• a carrier web containing synthetic resin is preferably used, in which the flaky pigment in the synthetic resin layer facing the carrier web is preferably present in an amount of 5 to 20% by weight, based on the synthetic resin.
• a particularly suitable and therefore preferred pigment of the desired spatial shape is mica, which has superficial metal oxides, preferably titanium dioxide or iron oxide. These are pearlescent pigments which give the synthetic resin layer a metallic effect in the process according to the invention. Such pigments are commercially available under the name Iriodin ® pigments.
• flake-shaped pigments are the metal pigments obtainable from metals or metal alloys by rolling and grinding.
• Ductile metals or alloys preferably aluminum, copper and silver, and brass and bronze alloys as alloys are preferably used to produce these pigments.
• metal oxides preferably iron oxides.
• a paper backing with a paper weight of 40 to 120 g / m 2 which is impregnated with a curable aminoplast resin in an amount of 80 to 150% of the paper weight and with at least two layers of a curable or thermosetting synthetic resin, each with a basis weight, is preferred from about 30 to 100 g / m2 is used.
• the synthetic resin can be colored with a dye that is soluble in the synthetic resin. To achieve special color effects, it is also possible to dye only the synthetic resin used to produce the top layer.
• the aminoplast resin used to impregnate the carrier flows, soaks and envelops the fibers of the carrier web and hardens. If a hardenable resin has been selected as the coating resin, this resin also begins to flow, forms a surface corresponding to the pressing tool and hardens. If a thermoplastic synthetic resin is used as the coating resin, it will also flow and adapt its surface to the pressing tool. In this case, however, it is necessary to cool the press under pressure until the thermoplastic resin has solidified again and can be removed from the press after cooling.
• the desired marbling effect occurs because, due to the uneven mass distribution in the paper, the flow of the resins takes place in the pressing process from areas of high density to areas of lower density.
• the resin flows faster in areas of lower density, and correspondingly more slowly in areas of higher density.
• the finely divided mica used according to the invention as a pigment is oriented when the resins flow due to its platelet-like shape in the direction of flow and reflects the flow structures. This effect is particularly enhanced and recognizable by the fact that the top resin layer is pigment-free.
• the flow of the resin is increased so that the orientation of the mica particles is further promoted.
• the surface obtained after pressing shows a decorative image that has a pronounced marbling due to the uneven distribution of the pigment.
• the pressing is carried out using a pressing tool which has no surface profiling.
• Profiling the pressing tool as described in DE-A-2 650 560, would hinder the free flow of the resins to areas of lower density and thus impair the orientation of the flaky pigments in the direction of flow. From this it is also understandable that a certain roughness depth of the surface of the press tool is allowed as long as the free flow of the resin is not hindered.
• the different flow of the coating resin can also be brought about or strengthened by regularly or irregularly arranging sections of a resin-coated carrier web under the carrier web to be used in the method according to the invention before pressing. These sections can be inserted, for example, to form a surface pattern. Such sections can have any geometrical shape and can be, for example, symmetrical or irregular. The sections can have the shape of a maple or oak leaf. It is also possible to insert dried natural leaves, such as oak leaves, which may have been impregnated with resin, the surface structures of the leaves being clearly visible. The inlaid sections stand out clearly from the surrounding surface in color and marbling.
• Lacquer films are known from the prior art, which consist of two layers, of which the lower layer contains mica-like pigments, while the upper layer (top layer) is pigment-free.
• Such e.g. Coatings known in the automotive industry for the production of metallic effect paints which include are described in DE-A-3 207 936 or DE-A-3 150 492, but differ significantly from the subject matter of the present invention in that no pressure is exerted on the substrate when the lacquer layers are applied and the flow processes described above do not take place .
• the pigments are evenly distributed in the paint layer. If the content of pigments in the lacquer layer is too low, only an iridescent effect occurs (DE-A-3 150 492, page 6 below). An uneven pigment distribution would also be in this case, e.g. when painting a car sheet, highly undesirable.
• the invention also encompasses the carrier web containing synthetic resin to be used in the process according to the invention, which is characterized in that it has two superimposed layers of a transparent, thermoplastic or thermosetting synthetic resin which is easily flowable under compression conditions, the synthetic resin layer facing the carrier web having a flaky (flake-like) form ) Contains pigment in an amount of 2 to 40 wt .-%, based on synthetic resin, and the outer synthetic resin layer is free of such pigments.
• the information already given applies here for the pigments to be used preferably or for the type of paper and the resins used for the impregnation and coating, which are preferably used as the carrier web.
• curable aminoplast resins such as, for example, the low molecular weight urea or melamine-formaldehyde resins or urea-melamine-formaldehyde resin mixtures, can be used as impregnation resins for the production of the carrier webs containing synthetic resin according to the invention.
• Curable, thermosetting or non-reactive, thermoplastic resins are suitable as coating resins.
• Suitable hardness Bare resins are the curable polyester resins based on esters of unsaturated or mixtures of saturated and unsaturated dicarboxylic acids in a reactive solvent such as styrene. Other suitable polyesters are described, for example, in DE-C-3 403 691 and DE-C-2 734 669.
• Curable acrylate or methacrylate resins or epoxy resins are also suitable as curable coating resins.
• Thermoplastic coating resins can be based on melamine resins etherified with short-chain, aliphatic alcohols. Further examples of suitable thermoplastic coating resins are polyester resins or acrylate-based resins.
• a fine cellulose paper with a basis weight of 80 g / m2 is used as the carrier web.
• the paper is colored with green pigments.
• the paper is impregnated with melamine-formaldehyde condensation resin and contains 80 g / m2 resin.
• the carrier web containing resin has a moisture content of 6 to 7%.
• the resin is composed as follows:
• the pigmented coating resin 50 g / m2 of the pigmented coating resin are applied to the carrier web using a doctor blade.
• the solvent is evaporated off in a drying tunnel at 40 to 80 ° C.
• the residual solvent content is then 8 to 9%.
• the transparent coating resin is then applied in the same amount and dried in the same way with a second metering unit.
• the pressing takes place in a multi-stage press at a pressure of 10 N / mm2, a temperature of 145 ° C and a pressing time of 20 minutes.
• the material to be pressed is recooled under pressure.
• a laminate with a brown marbled surface is obtained.
• the carrier web described in Example 1 is coated.
• 50 g / m2 of the pigmented coating resin are knife-coated onto the carrier web.
• the solvent is evaporated off in a drying tunnel at 50 to 80 ° C.
• the transparent, unpigmented resin is applied in the same way and the product obtained is dried.
• the pressing takes place in a multi-stage press at a pressure of 10 N / mm2, a temperature of 145 ° C and a pressing time of 45 minutes.
• the material to be pressed is recooled under pressure.
• a plate with decorative marbling, tempered on both sides, is obtained.
• a carrier web, as described in Example 1, is coated.
• the coated carrier web is produced analogously to Example 1.
• the pressing takes place in a multi-stage press at a pressure of 2 N / mm2, a temperature of 145 ° C and a pressing time of 12 minutes.
• the material to be pressed is recooled under pressure.
• the tempered plate obtained shows a decorative marbling and is excellently suited for interior design purposes (furniture, exhibition purposes).
• Example 2 The procedure of Example 1 is repeated, but 4 g of the solvent-soluble dye Zaponblau 807 are added to the transparent coating resin. The result is a surface coloring with the marbling according to different blue coloring.
• a carrier web, as described in Example 1, is coated.
• the coated carrier web is produced analogously to Example 1, and the production of a surface-coated chipboard analogously to Example 3.
• a coated plate is obtained which has a silver metallic marbling and is particularly suitable for producing decorative surfaces.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Laminated Bodies (AREA)

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Cited By (5)

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Citations (6)

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• 1988
  • 1988-08-29 EP EP88114031A patent/EP0357808A1/fr not_active Withdrawn
• 1989
  • 1989-07-27 US US07/387,027 patent/US5034084A/en not_active Expired - Fee Related

Patent Citations (6)

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